Method for preparing continuous carbon fiber-reinforced thermoplastic prepreg

Abstract

The present invention relates to a method for preparing a continuous carbon fiber-reinforced thermoplastic prepreg, and more specifically, to a method for preparing a continuous carbon fiber-reinforced thermoplastic semi-prepreg or prepreg, comprising the steps of: providing a plurality of carbon fibers having an increased width; preparing a layered product by arranging a thermoplastic film on at least a part of the upper and lower portions of the carbon fibers having an increased width; and preparing a joined product by joining the thermoplastic film and the carbon fibers comprising the layered body.

Description

TECHNICAL FIELD[0001]The present disclosure relates to a method for manufacturing a continuous carbon fiber reinforced thermoplastic prepreg, and more particularly, to a method for manufacturing a continuous carbon fiber reinforced thermoplastic prepreg by disposing a carbon fiber layer between a plurality of layers of thermoplastic film and bonding the carbon fiber layer and the layers of thermoplastic film to each other instead of directly impregnating the carbon fiber with melted thermoplastic resin.BACKGROUND ART[0002]Generally, continuous carbon fiber reinforced thermoplastics are formed by continuously embedding a reinforcing fiber such as a glass fiber or a carbon fiber in a plastic having a relatively low degree of mechanical strength. Such continuous carbon fiber reinforced thermoplastics have very high degrees of mechanical strength, rigidity, and impact resistance, as compared to short fiber reinforced thermoplastics (SFTs) having reinforcing fibers contained therein havi...

AI Technical Summary

Benefits of technology

The present invention is a method of manufacturing high-strength, lightweight continuous carbon fiber reinforced thermoplastic plates by using a unidirectional or bi-axial arrangement of a continuous carbon fiber prepreg impregnated with a thermoplastic resin film. This method eliminates the need for an additional resin impregnating process and allows for easy weaving of different thermoplastic films. The resulting carbon fiber reinforced thermoplastic products have a high degree of strength and are maximized through impregnating the carbon fiber with a more viscous thermoplastic resin, minimizing voids, and maximizing the volume fraction of the carbon fiber.

Problems solved by technology

Although the degree of impregnation may be increased by optimizing process conditions of a pultrusion process, it is difficult to control the amount of a reinforcing fiber such as a continuous fiber and the amount of a plastic resin being mixed, and continuous fibers processed by the pultrusion method may not be easily woven due to having a low degree of flexibility.

Furthermore, if a heating method of the related art is used, films may be melted from surfaces thereof, and thus the films may be easily bent on the melted surfaces.

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